The precision forging technology is the favored means to improve the machining accuracy and efficiency of aero-engine blade manufacturing. However, there is still a certain geometric deviation between the forged blade surface and the design model, causing the edges of the blade machined based on the design model cannot match well with the blade body. To solve this issue, a geometric reconstruction method for adaptive machining of the precision forged blade is proposed. The objective function of match is established based on the tolerance constraint, and the Particle Swarm Optimization (PSO) algorithm for solving this objective function is presented. A smoothing reconstruction algorithm is proposed to predict the profile of the edge shape based on deformation trend of the blade surface. Experiments verify effectiveness of the approach and algorithm proposed in this paper. The results show that this method can reconstruct a qualified model for high-efficiency and precision requirements of adaptive machining of the precision forged blade. This approach is finally verified with a precision forged blade by the adaptive CNC machining.
FENG Yazhou
,
REN Junxue
,
LIANG Yongshou
,
LIU Mingshan
. Multi-objective optimization algorithm for geometric reconstruction of precision forged blade[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2018
, 39(7)
: 421844
-421844
.
DOI: 10.7527/S1000-6893.2018.21844
[1] LU B, OU H, ARMSTRONG C G, et al. 3D die shape optimisation for net-shape forging of aerofoil blades[J]. Materials & Design, 2009, 30(7):2490-2500.
[2] 任军学, 冯亚洲, 米翔畅, 等. 航空发动机精锻叶片自适应数控加工技术[J]. 航空制造技术, 2015, 492(22):52-55. REN J X, FENG Y Z, MI X C, et al. Adaptive techniques in CNC machining of aeroengine precision forging blades[J]. Aeronautical Manufacturing Technology, 2015, 492(22):52-55(in Chinese).
[3] MAKEM J E, OU H, ARMSTRONG C G. A virtual inspection framework for precision manufacturing of aerofoil components[J]. Computer-Aided Design, 2012, 44(9):858-874.
[4] ZHANG D H, ZHANG Y, WU B H. Research on the adaptive machining technology of Blisk[J]. Advanced Materials Research, 2009, 69-70:446-450.
[5] GAO J, CHEN X, YILMAZ O, et al. An integrated adaptive repair solution for complex aerospace components through geometry reconstruction[J]. International Journal of Advanced Manufacturing Technology, 2008, 36(11-12):1170-1179.
[6] JAVIDRAD F, RAHMATI R. An integrated re-engineering plan for the manufacturing of aerospace components[J]. Materials & Design, 2009, 30(5):1524-1532.
[7] MOHAGHEGH K, SADEGHI M H, ABDULLAH A. Reverse engineering of turbine blades based on design intent[J]. International Journal of Advanced Manufacturing Technology, 2007, 32(9-10):1009-1020.
[8] MOHAGHEGH K, SADEGHI M H, ABDULLAH A, et al. Improvement of reverse-engineered turbine blades using construction geometry[J]. International Journal of Advanced Manufacturing Technology, 2010, 49(5-8):675-687.
[9] DONG Y, ZHANG D, BU K, et al. Geometric parameter-based optimization of the die profile for the investment casting of aerofoil-shaped turbine blades[J]. International Journal of Advanced Manufacturing Technology, 2011, 57(9-12):1245-1258.
[10] ZHAO Z, FU Y, LIU X, et al. Measurement-based geometric reconstruction for milling turbine blade using free-form deformation[J]. Measurement, 2017, 101:19-27.
[11] LI Y, NI J. Constraints based nonrigid registration for 2D blade profile reconstruction in reverse engineering[J]. Journal of Computing & Information Science in Engineering, 2009, 9(3):296-297.
[12] RONG Y, XU J, SUN Y. A surface reconstruction strategy based on deformable template for repairing damaged turbine blades[J]. Proceedings of the Institution of Mechanical Engineers Part G:Journal of Aerospace Engineering, 2014, 228(12):2358-2370.
[13] LI L, LI C, TANG Y, et al. An integrated approach of reverse engineering aided remanufacturing process for worn components[J]. Robotics and Computer Integrated Manufacturing, 2017, 48:39-50.
[14] 蔺小军, 陈悦, 王志伟, 等. 面向自适应加工的精锻叶片前后缘模型重构[J]. 航空学报, 2015, 36(5):1695-1703. LIN X J, CHEN Y, WANG Z W, et al. Model restructuring about leading edge and tailing edge of precision forging blade for adaptive machining[J]. Acta Aeronautica et Astronautica Sinica, 2015, 36(5):1695-1703(in Chinese).
[15] 张艳, 汪文虎, 解晓娜, 等. 压气机辊轧叶片前后缘圆滑转接建模方法[J]. 计算机集成制造系统, 2015, 21(2):444-448. ZHANG Y, WANG W H, XIE X N, et al. Smooth connection modeling method between edge and body of compressor roll-forming blade[J]. Computer Integrated Manufacturing Systems, 2015, 21(2):444-448(in Chinese).
[16] 程云勇, 王嫔, 刘鹏军, 等. 基于误差控制的薄壁叶片椭圆弧形前后缘建模方法[J]. 计算机辅助设计与图形学学报, 2016, 28(1):155-161. CHENG Y Y, WANG P, LIU P J, et al. An error control based modeling method for ellipse leading edge and trailing edge reconstruction of thin-walled blade[J]. Journal of Computer-Aided Design & Computer Graphics, 2016, 28(1):155-161(in Chinese).
[17] 侯斐茹, 万能, 常智勇, 等. 轮廓度约束下近净成形叶片余量优化方法[J]. 航空学报, 2017, 38(7):299-308. HOU F R, WAN N, CHANG Z Y, et al. An allowance optimization method for near-net shape blade under profile tolerance constraints[J]. Acta Aeronautica et Astronautica Sinica, 2017, 38(7):299-308(in Chinese).
[18] ZHANG Y, CHEN Z T, NING T. Reverse modeling strategy of aero-engine blade based on design intent[J]. International Journal of Advanced Manufacturing Technology, 2015, 81(9-12):1781-1796.
[19] XU G, WANG G Z, CHEN W Y. Geometric construction of energy-minimizing Bézier curves[J]. Science China Information Sciences, 2011, 54(7):1395-1406.
[20] 施法中. 计算机辅助几何设计与非均匀有理B样条[M]. 北京:高等教育出版社, 2001. SHI F Z. Computer aided geometric design and non-uniform rational B-spline[M]. Beijing:Higher Education Press, 2001(in Chinese).
[21] PIEGL L, TILLER W. The NURBS book[M]. 2nd ed. New York:Springer-Verlag, 1997.
CJA